Heat processed food base

ABSTRACT

A heat processed food base which is formed by heating a batter which is obtained by kneading wheat flour, an oil or fat, sugar, an edible surfactant such as egg, and water and which is poured onto a heating plate and spread thereon, the heating being performed between heated plantens at a certain temperature for a given time in such manner that the starch of the batter is changed to α-starch, and the protein therein is coagulated by heat, and a small amount of water remains, so that edible vessels having crispness and good taste, for instance for use as ice cream cones, can be formed by a second baking, at a higher temperature.

BACKGROUND OF THE INVENTION

The present invention relates to a heat-processed food base, andparticularly to a heat-processed food base which is useful for producingedible vessels having the form of a cone such as waffle cones, in whichices such as soft ice cream, ice cream or various other food materialsare placed, i.e., waffle cones and square vessels called tarts, each ofwhich is desired to have a small apparent specific gravity, porosity,light weight and a crisp taste.

Edible vessels which are filled with ices such as soft ice cream or icecream and sold are generally formed in cone shapes by baking a batterobtained by kneading a mixture containing a basic ingredient such aswheat flour and a larger amount of water in a high-temperature heatingplate by a manufacturer who specializes in producing such cones. Theseedible vessels are then packed and delivered to outlets for selling icecream. However, since one merit of waffle cones are their very crispytaste, waffle cones involve many problems with respect to the difficultyof handling them during baking, as well as after baking and delivery tothe sales outlets for ice cream, because waffle cones have very poorresistance to shock and are thus easily damaged.

To remove the aforementioned disadvantages, the present inventorpreviously proposed has a method of producing edible vessels, disclosedin Japanese Patent Application No. 26982/1984, in which water is addedto a basic ingredient such as wheat flour in such an amount that theflour is formed into a dough and is kneaded, the thus-obtained mixturebeing spread to a given thickness, and the materials having a requiredshape then being obtained from the spread dough plate by wrapping orrolling it into cone shapes and hardening to cone shapes immediatelyafter baking to obtain edible vessels.

However, in the above-described prior art, the former method has aproblem in that, since cone-shaped edible vessels which are hardenedimmediately after baking are shipped, the cone-shaped edible vessels areeasily damaged when shipped, for example, about 20 to 30% of the wafflecones shipped will be no good. In order to avoid this problem, theformer method may be employed at the side of a user, i.e., the outletsof a soft ice cream distributer. However, this involves many problems.One is that the level of equipment investment for such items as a bakingmachine and an apparatus for preparing materials is increased, and thereare sometimes limits on the space available for installing suchequipment in sales outlets regardless of the difficulty of handlingwaffle cones and the technique of baking a material which is required,regardless of the amount of the material. It is also difficult to ensurethat workers acquire the necessary technique for handling a bakingmachine and arrange for the supply of the required amperage of electricpower when such equipment is installed at sales outlets where ice creamis sold, because they are often temporary employees or part-timeworkers. Thus, the former method cannot be readily employed in theoutlets where ice cream is sold.

On the other hand, the latter method also involves many problems, forexample, the fact that waffle cones having a crispy taste cannot beobtained.

The most important reason for the use of wheat flour as a confectionaryingredient is that wheat flour contains protein, unlike rice flour,potato flour and the flour of other grain, most of which consists ofstarch alone.

Starch is changed to an α-form by water and heat and plays a principalrole in forming the shapes of various kinks of confectionary, as well asbeing an ingredient thereof. With respect to its suitability in theprocessing of confectionary, wheat flour has processing properties whichare mainly determined by the protein contained therein, together withstarch as a main component thereof, unlike other types of flour used asbasic ingredients of confectionary such as rice flour and potato flour.The properties of wheat flour which are so different from the othertypes of flour used for confectionary are attributed to its proteincomponent.

Wheat flour greatly differs from other basic ingredients forconfectionary in the point that, when wheat flour is kneaded with water,the protein molecules contained therein absorb water, hydrate, and arebonded to each other to form a network structure consisting of stickyand elastic gluten. It could be said that the present invention is basedon control of the water and heat used for changing starch to an α-form,as well as control and supervision of the employment of gluten, andclarification of its behavior.

Wheat flour is classified according to the properties and amounts ofprotein contained in it, i.e., strong flour, medium flour and weakflour. This classification is based on the amounts and properties ofgluten produced by the protein, and the use of wheat flour depends uponthese amounts and properties.

    ______________________________________                                        Class    Protein content (%)                                                                         Gluten   Main use                                      ______________________________________                                        Strong flour                                                                           12-14         Strong   Bread, Chinese                                                                noodles                                       Medium flour                                                                           8-11          Slightly Wheat vermicelli                                                     strong                                                 Weak flour                                                                             7-8           Weak     Confectionary                                                                 Tempura                                       ______________________________________                                    

In general, weak flour containing a small amount of protein is used inproducing confectionary, and is kneaded with sugar, oil and fat, salt,eggs, milk, spices and coloring agents, together with water, to form abatter or dough which is then subjected to heat processing. In this heatprocessing, the starch contained in the wheat flour is changed toα-starch, and the protein which forms gluten is subjected toirreversible heat denaturation (heat coagulation) to provide foods in adigestible state with a good taste. General confectionary is basicallyproduced by the above-described method, employing wheat flour as themain ingredient.

When wheat flour is kneaded with water, it immediately absorbs water,the amount of water absorbed by the starch being 30% of the weightthereof, and the amount of water absorbed by the protein being 200% ofthe weight thereof. The water, becomes chemically-bound water whichcauses the starch to solate and the protein molecules to be bondedtogether to form sticky and elastic gluten. The starch so producedstarts to gel at about 54° C. with the viscosity thereof beingincreased, and finally becomes α -starch which is edible and digestible.If heating is further continued, the α-starch is dehydrated to becomesolidified.

On the other hand, gluten forms a three-dimensional spongy networkstructure, leading to the formation of strong skeletons of theconfectionary due to irreversible heat denaturation of the proteinduring heating.

Although hard confectionaries which are hard to masticate, such ascrackers and hard biscuits, are produced in the aforementioned manner,porous foods which are finally supposed to have a crisp taste and towhich the present invention relates may be produced by the methoddescribed below. A wheat flour ingredient is kneaded with water so thatany bubbles produced in the kneaded batter are included in the networkstructure formed by the gluten due to the presence of egg or the ediblesurfactant consisting of a synthetic frothing emulsifier contained inthe basic material. These bubbles included in the network structure makethe gelled α-starch, which is a main component of the processing basematerial, porous as a result of the solidification which occurs due tothe heat denaturation of the gluten upon heating. If heating iscontinued, the processing base material is dehydrated, and the starch issolidified to form a porous confectionary body. However, with respect tocrispness, the body itself becomes hard, as a whole, due to the strongthree-dimensional network structure formed by the gluten, even if it isporous.

Therefore, if an oil or fat is kneaded with the material base, the oilor fat is spread in a film form in the material base by the function ofthe above-described edible surfactant to prevent the binding of thenetwork structure of gluten, whereby the end products can be providedwith fragility crispness and a good taste.

Conventional confectionaries such as wafers and waffles which arecharacterized by crispness, fragility and a good taste can be obtainedby heating the basic material until almost all the water therein hasbeen released and further continuing the heating to a temperature above200° C.

Edible vessels for ice cream are generally formed into thin-skinnedcones called waffle cones or dish-like shapes immediately after theproducts having fragility crispness and a good taste have been obtainedby the above-described processing and before the products have cooled.Therefore, such vessels have very weak resistance to impact, and will bedamaged during delivery to sales outlets where the vessels are filledwith ice cream and sold, because the cones or dish-like forms of vesselsare damaged when delivered to users, if each of them is notappropriately packed.

SUMMARY OF THE INVENTION

The present invention is capable of solving the above-described problemsand of preventing any damage of edible vessels by allowing a basicmaterial to be baked to form a cone or dish-like shape at a salesoutlet. It also has the effect of attracting customers' interest withthe pleasant smell generated when the basic material is baked in thesales outlet without any other smells being created. An additionaladvantage of the present invention is that it allows consumers torecover the sense of taste of their tongue after it has been blunted byeating ice cream and yet also allows them to experience the originaltaste of the ice cream.

There is provided a method in which wheat flour is kneaded with watercontaining sugar, oil or fat, and other ingredients, and the obtainedmixture is poured onto a heating plate to form waffles which are thenfilled with ice cream and sold. However, as described above, wheat flourrapidly forms a strong network structure of gluten, if the temperatureand agitation conditions are not strictly controlled during the kneadingwith water, even if weak flour containing a small amount of protein isemployed.

Starch is responsible for the formation of the overall shape of theconfectionary product, while gluten is responsible for the production ofthe stickiness of the basic material used to form the confectionary,that is, the so-called batter or dough, as well as hardness of the finalconfectionary product.

The crispness and good taste depend upon the size, amount and uniformityof distribution of the bubbles contained in the basic material forbaking, which greatly depend upon the amount of gluten and the networkstructure formed thereby. For example, the structure and amount of thegluten formed allow a suitable amount of bubbles of an appropriate sizeto be uniformly held in the material and also allow the expansion of thebubbles due to heating at the time of the baking of the material to bekept at an appropriate and uniform level.

If there is no gluten, the appropriate amount of bubbles of suitablesize will be lost from the confectionary products like the froth on aglass of beer and will not serve to appropriately expand the body ofeach product.

It is necessary to strictly control such work, particularly the work inwhich the basic confectionary material containing wheat flour as a mainingredient is produced such that the gluten network is formed, and theprocess in which the produced material is baked to form a confectionarymaterial which can then be formed into products suitable for sale. Itcan be said that such work is not easily performed at the kind of salesoutlet where ice cream is usually sold by part-time workers. It is thusan object of the present invention to solve this difficulty and toprovide a food base material which can be formed into final productssuch as waffle cones that can serve as light ice cream vessels, with acrispy texture, at a sales outlet for selling ice cream, without anydanger of damage, and which not only allows the final products togenerate a pleasant smell when being baked, but which also enableseasily-finished products to be prepared in such a manner that they canbe served still hot from a heating plate and filled with ice cream suchas to give the customers an adequate feeling of satisfaction.

The present invention provides a superior basic material which is formedby mixing water and main ingredients such as wheat flour, oil or fat,eggs, and so on, that are stored at a suitable temperature and humidityin an appropriate mixing ratio in a strictly controlled manner,appropriately heating the thus-obtained batter to form α-starch and forman appropriate gluten network that is not too strong and has a suitablearrangement, and heat-hardening the batter while appropriatelydispersing bubbles, which would affect the crispness of the products,and controlling the heat volatilization of the bubbles to form firststage products having an appropriate skeleton; the thus-obtained firstproducts containing an appropriate amount of water so that they canretain sufficient softness to prevent any damage during delivery to icecream sales outlets and during handling at the outlets, whereupon wafflecones which are the same as those produced at factories can be formed bya simple quick process at the outlets, heat energy being effectivelyutilizable when the first stage products are baked at the outlets.Therefore, if the first stage products are produced by strictlycontrolling all the processes, they can be easily baked at the outletsto form waffle cones, even by inexperienced, part-time workers, whilesimultaneously generating a pleasant smell.

In other words, the gist of the present invention is that an appropriateamount of oil or fat is mixed with wheat flour in order to prevent thenetwork structure of gluten from being made too strong; an ediblesurfactant such as egg is mixed with the obtained mixture to help oil orfat films to extend by the frothing emulsification action thereof andalso to help small bubbles to be maintained in a confectionary textureso that the final products maintain crispness and a good taste; sugarand salt are mixed with the obtained mixture so as to facilitate thesefunctions; and appropriate flavors are added to the obtained mixturewhich is then sufficiently and uniformly kneaded with a suitable amountof water to form a batter; the batter then being heated in such a mannerthat the starch of the wheat flour is changed to α-starch and gluten issolidified by heat to form a network structure having an appropriatestrength due to the hydration of the protein, and being further heatedunder conditions which are controlled to ensure that the water remainsin an amount (preferably 7 to 20 percent) sufficient to prevent excessenergy from being consumed during baking at the sales outlets and tomaintain the softness of the batter so that the baked products are notdamaged during delivery to the outlets. For example, the temperature maybe about 110 to 140° C., which is very much lower than that used inconventional methods of producing confectionary and the time is as shortas 30 to 90 seconds. This basic food material heated at a lowtemperature for a short time can easily be formed into, for example,waffle cones simply by finally baking it at a temperature of 180° to220° C. for 45 to 60 seconds at the ice cream sales outlets, without anyneed to consider any factors other than the baking temperature and time.In addition, the basic food material enables light ice cream vesselshaving crispness and a good taste to be formed by a two-stage method ofbaking, using wheat flour as a main ingredient.

The process involved, up to the point where the heated basic foodmaterial is formed, is critical and a difficult process for producing abasic food material for waffle cones which have a good crisp taste andwhich are thin and brittle. Inexperienced people such as part-timeworkers basically lack the ability to perform such a process at thesales outlets for ice cream as such sales outlets have very fewfacilities and means for controlling the process. However, if the heatedbasic food material of the present invention is used, waffle cones caneasily be formed simply by finally heating the basic material so as toheat-volatize the 4% to 20% water which is retained in the basicmaterial for the purpose of maintaing its softness during delivery. Ifthe remaining water is volatized by heating, the basic material at atemperature of 170° C. or higher, at which temperature the sugar in thebasic material is caramelized, and the basic material is thereby given adesirable color, such as light brown. At all events, the heated basicfood material of the present invention enables waffle cones to be easilyformed.

Consequently, the basic material enables the heating process to bedivided into a heating stage that is conducted at a factory which hasthe capacity to ensure adequate control, and a final heating stageperformed at the sales outlets for ice cream, that is two-stage baking.In this way, foods such as hot waffles which are formed by using wheatflour as a main ingredient and which are brittle and have a good tastecan be produced while generating a pleasant smell and yet avoiding anydanger of damage.

Rice crackers, one sort of rice cake, have been made in Japan for manycenturies and these are also heated in a two-stage process. However,this process is performed to allow drying at a temperature below 100° C.and thus must be called a two-stage drying process. Nonglutinous riceflour as a main ingredient is steamed, kneaded with water and rolled toform a plate-like shape. Portions of this dough for rice crackers arecut off from the plate to produce given shapes and then dried in an ovenat 70° to 75° C. until the water content becomes about 20%. This stageis called first drying. The dried portions of dough obtained are allowedto stand at room temperature for a long time to form translucent, glassydough portions for rice crackers. To form these dough portions into ricecracker products, they are again dried in an oven until the watercontent becomes about 10 to 15% in a second drying. After the seconddrying, the dough portions are directly baked by a fire at 200° to 260°C. and flavored with a seasoning such as soy sauce to form rice crackerproducts.

This method differs from the two-stage method of baking a wheatflour-based material of the present invention, and this two-stage dryingmethod is required for to allow crackers containing bubbles to be formedby using rice flour having no gluten network, rice cake having a viscousstructure.

An explanation will now be given of the fundamental difference betweenrice crackers, sliced and dried rice cake, and a processed food baseobtained by baking a wheat flour-based material in a two-stage manner asin the present invention.

Starch of rice flour, which is a main ingredient of rice cake, mainlyconsists of aminopectin and has thermal expansibility. On the otherhand, the starch of wheat flour has no thermal expansibility and thusmust be used in combination with egg or a synthetic edible surfactantthat can serve as a frothing agent.

A more important difference is that wheat flour contains protein as wellas starch, as described above, and the various kinds of confectionaryingredients other than wheat flour have no three-dimensional networkstructure like that of wheat flour, which depends upon the quality andamount of gluten produced by water absorption and hydration of theprotein contained therein. Therefore, for example, rice cakes, andparticularly rice crackers, are expanded due to thermal expansion of theaminopectin which is a main component of the starch of rice flour, butwhen a mixture of rice flour and water is kneaded, rice cake having ahigh viscosity is formed, because the bubbles which are included thereinduring the kneading of the mixture are not released. This rice cake isappropriately shaped, then dried in an oven at 70° to 75° C. until thewater content becomes about 20% (first drying), and allowed to stand fora long time to form a dough for making rice cakes. Before the dough isbaked, it is again dried, as described above, until the water contentbecomes 10 to 15% (second drying), and then baked by direct fire at 200°to 260° C. and is flavored with a seasoning such as soy source to form aproduct. This method of producing rice crackers is fundamentallydifferent from the two-stage method of producing a brittle type ofconfectionary having crispness and a good taste.

It is an object of the present invention to remove the aforementioneddisadvantages and various problems and to provide a heated food basewhich is useful in the production of edible vessels called waffle coneswhich have a small apparent specific gravity, crispness, and a goodtaste.

The above-mentioned object of the present invention can be achieved byheating a batter which is obtained by kneading wheat flour, an oil orfat, sugar, an edible surfactant such as egg and water, and which ispoured onto a heating plate and spread thereon, the heating beingconducted at relatively low temperature at which the starch in thebatter is changed to α-starch, the protein is heat-coagulated, and about4% to 20% of water remains in the heated product.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings show an embodiment of the present invention:

FIG. 1(a) is a perspective view of a baking machine;

FIG. 1(b) is a sectional view of the baking machine during baking;

FIG. 2(a) is a perspective view of a final-stage baking machine;

FIG. 2(b) is a perspective view of the final-stage baking machine in astate different from the state shown in FIG. 2(a);

FIG. 2(c) is a sectional view taken along the line A--A in FIG. 2(d);

FIG. 2(d) is a sectional view taken along the line B--B in FIG. 2(c);

FIG. 3 is a schematic drawing of an example of a process of producing anedible vessel from a base; and

FIG. 4 is a perspective view of an example of the edible vessel obtainedby the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

In the present invention, and as shown in FIGS. 1(a), 1(b), sugar ismixed with wheat flour to add appropriate sweetness thereto, and an oilor fat, egg serving as an edible surfactant exhibiting the functionswith respect to frothing, emulsification and stable maintenance ofbubbles or a synthetic compounded edible surfactant exhibiting the samefunctions are added to the mixture, as well as, if required, bakingpowder, salt, milk, flavoring and coloring agents. The thus-obtainedmixture is poured into a mixer, and water is added to the mixture in anamount capable of making a heated product porous and light,corresponding to the ingredients used. The obtained mixture is kneadedto form a batter 2. A given amount of the batter 2 is placed on a lowerplate 10a of two heating plates 10 and formed into a kneaded disc-shapedbase 2A which is then heated to obtain a heated food base 11.

The heated food base 11 is stored while being cooled and may be formedinto edible vessels such as cones by heating it again (final-stagebaking) or may be eaten as it is.

For example, the heated food base 11 stored is tightly packed anddelivered to users such as outlets for selling ice cream where the foodbase is taken out of the package, inserted between electric heaters 17,17 through iron plates 18, 18 in the toaster-like shape of heating case20 shown in FIGS. 2(a) to 2(d), and heated to a temperature above 170°C. until the surface thereof becomes light brown to obtain a finallybaked base 11A which is called a baked product and which is the same asthat obtained by a conventional method of continuous baking. This finalbaked base 11A is immediately sent to the usual vessel forming machine12 for cones shown in FIG. 3 in which the base 11A is formed into acone, and then hardened by cooling to obtain the cone-shaped ediblevessel 14 shown in FIG. 4.

If the heating plates 10 used for baking the batter are each providedwith a checkered pattern 4, the heated food base 11 can be patternedaccordingly, whereby an edible vessel 14 having a checkered pattern canbe obtained.

The edible vessel 14 is slightly cooled by the cone forming machine 12during the shaping and then becomes hardened. Thus, the cone-shapededible vessel 14 retains its shape and can thus be filled with ice creamand sold at the sales outlet.

Since the heated food base 11 has been previously heated, the starch ischanged to α-starch, and the protein is coagulated and skeletonized tosome extent. However, the heated food base 11 maintains some flexibilityand is not broken when bent, nor it is significantly damaged whensubjected to impact. This is because of the presence of oil or fat filmsthat permeate between the starch and the protein and the remaining waterwhich contains an appropriate amount of sugar. Therefore, the heatedfood base 11 remains substantially undamage during delivery, whichsolves the prior art problem with respect to the difficulty of delivery.In addition, since the heating is performed at a temperature at whichthe starch is changed to α-starch and the protein is heat-coagulated,the heating time can be reduced and environmental changes in thevicinity of the location of the first-stage baking can be reduced,because only a small amount of heat is generated. Furthermore, since thefinal baking is performed by heating the food base until the surfacethereof becomes light brown, the baking time at sales outlets for icecream can also be reduced, and the problem with respect to thegeneration of heat here can be substantially solved also.

An embodiment of the present invention is described below.

Embodiment 1

    ______________________________________                                        Wheat flour         80-120                                                    Sugar              30-60                                                      Oil or fat         10-30                                                      Egg                10-30                                                      Monogly (glycerin mono-                                                                          0.5-2                                                      fatty acid ester)                                                             Powdered milk      3-5                                                        Salt               0.5                                                        Coloring and flavoring                                                                           small                                                      agents             amount                                                     Water               80-120                                                    ______________________________________                                         (Each numerical value shows the compounding ratio by weight.)            

A batter 2 was obtained by well-agitating and mixing the ingredients ofEmbodiment 1 shown in the accompanying Table. The obtained batter 2 waspoured into the lower heating plat 10a of the two heating plates 10which were each patterned with a lattice comprising squares having 10-mmsides, the surfaces of which ware heated at about 120° to 150° C. Anupper heating plate 10b was pressed on the lower heating plate 10athrough a hinge 10c, and the batter 2 held between the two heatingplates 10a, 10b was baked by heating in such a manner that the batterwas kept at about 110° to 140° C. for a given time. Then, the heatingplates 10a, 10b were opened to take out a heated food base having a discshape which was the heated food base 11.

The conditions of pouring of the batter were as follows:

1. The amount of the batter poured at one time: about 25 to 30 g

2. The temperature of the upper and lower heating plates: 120° to 150°C.

3. The thickness of the batter poured was determined by the gap betweenthe two heating plates, the gap being set to a value substantiallyequivalent to the thickness of the heated food base.

The conditions of heating the batter were as follows:

1. The gap between the heating plates was equivalent to the thickness ofthe heated food base (the disc-shaped heated base).

In these examples, the gap was 2.5 mm.

2. The heating temperature was 120° C., the temperature of the heatingplates was 150° C., and the heating time was 30 to 90 seconds.

Heating temperature: 120° C., 140° C., 150° C.

Heating time: 60 seconds, 75 seconds, 90 seconds (at 120° C.);

60 seconds, 75 seconds (at 140° C.); 45 seconds, 60 seconds (at 150° C.)

3. The features of the heated base (disc-shaped heated base) and theremaining water (measured by a moisture meter produced by Ketto Co.,)

(1) First-stage baking

    ______________________________________                                                      Feature    Water content                                        ______________________________________                                        (111) (110° C., 45 seconds)                                                            White, soft  19.6%                                            (112) (110° C., 60 seconds)                                                            Slightly-    18.2%                                                            yellowish white                                                               soft                                                          (121) (110° C., 75 seconds)                                                            Yellowish white                                                                            17.6%                                                            soft                                                          (122) (120° C., 40 seconds)                                                            Yellow inclining                                                                           16.8%                                                            toward white,                                                                 soft                                                          ______________________________________                                    

In particular, the heated food bases containing large amounts of water(17 to 20%) were soft, and when ten sheets of such bases having adiameter of 160 mm were piled up and a load of 3 g/cm² was appliedthereon, these bases adhered to each other. However, they could beeasily separated from each other without being damaged. The latticepattern on each base also was not damaged. Although the heated foodbases containing 15 to 17% of water were similarly soft, when ten sheetsof such bases were piled up and a load of 5 g/cm² was applied thereon,the bases were not adhered to each other. The heated food basescontaining 15 to 19% of water were not broken when they were bent at anangle of about 180°.

In any case, the heated food bases with a lattice pattern having aheight of about 1.5 mm and 10-mm squares could be obtained. Althoughthese food bases can be eaten as they are because the starch of wheatflour is changed to α-starch, if they are finally baked by heating themin such a manner that the surfaces thereof become light brown, foodbases for edible vessels having a crispness and a good taste can beobtained.

When all the heated food bases heated under the above-describedconditions were finally baked at 220° C. for 60 seconds (second baking),disc-shaped baked products of brownish yellow which contained about 0.3to 0.4% of remaining water and had crispness and a good taste wereobtained.

Since no cracks are produced on the products (bases) of the first bakingwhen they are bent, the food bases can be delivered without any dangerof damage.

Although such food bases will be adhered to each other by pressure, theadhesion can be prevented by waxing or interposing films such as polymerfilms between the bases. Therefore, when a given number (about 10 sheetsin one package) of the food bases are put in plastic bags and, ifrequired, the plastic bags are piled up in a corrugated cardboard box,the bases can be transferred without being compressed, if corrugatedcardboard is interposed between the respective bags put in layers.

(2) Second-stage baking (final-stage baking)

After the first stage-baked heated food bases had been stored in a darkplace at 10° C. for 24 hours, they were finally baked by using thetoaster-like form of heater shown in FIGS. 2(a) to 2(d). The heater wasprovided with heaters 17 made of nichrome wires, and iron plates 18,which were provided on the surfaces of the heaters, had a thickness ofabout 2 mm. The iron plates were heated so as to form heating flatplates with a substantially uniform distribution of temperatures. Two ormore heated food bases obtained by heating under the same conditionswere suspended one by one between the two heating flat plates at a giventemperature for a given time so that the surfaces thereof were heated toform products. The temperature of the surface of each of the heatingflat plates was 180° to 190° C., and the gap between the two heatingflat plates was about 15 mm. Therefore, the distance between each of thesurfaces of the heated food base and the surface of each flat plate wasabout 5 mm. Consequently, when one of the finally baked discs was formedto a cone shape by using a machine before the sugar ingredient was nothardened due to a decrease in the temperature, a cone product could beobtained. The states of the finally baked disc products which werecooled without being shaped are described below.

Features and contents of remaining water of finally-baked products discproducts

    __________________________________________________________________________    Heated   Condition of                                                                          Final feature and                                            food base                                                                              final baking                                                                          taste       Water content                                    __________________________________________________________________________    (211)                                                                             (111)                                                                              180° C., 60 sec.                                                               Yellowish brown, many                                                                     0.38%                                                             bubbles, crisp taste                                         (212)                                                                             (112)                                                                              180° C., 90 sec.                                                               Brown, slightly harder                                                                    0.35%                                                             than (211)                                                   (221)                                                                             (121)                                                                              180° C., 60 sec.                                                               Light brown, the taste                                                                    0.36%                                                             similar to (212)                                             (222)                                                                             (122)                                                                              180° C., 90 sec.                                                               Slightly dark brown,                                                                      0.31%                                                             the same taste as (212)                                      __________________________________________________________________________

Although any one of the products had crispness and a taste and goodstate, feelings that the tastes slightly depend upon the differences inthe baking conditions were obtained.

The water contents were within the range of 0.3 to 0.4%, and it wasfound that the conditions of first baking slightly affect the finallybaked products. Embodiment 2

An embodiment using a synthetic surfactant is described below.

    ______________________________________                                        Wheat flour          80-120                                                   Sugar               30-60                                                     Oil or fat          10-30                                                     Edible surfactant   2-6                                                       Baking powder       0.5-1.5                                                   Powdered milk       3-5                                                       Salt                0.5-1.0                                                   Other ingredients (coloring                                                                       small                                                     and flavouring agents                                                                             amount                                                    Water                80-120                                                   ______________________________________                                    

The edible surfactant shown in the table was a compounded substance of aglycerin fatty acid ester and a cane sugar fatty acid ester.

The ingredients shown in the accompanying Table were well agitated andmixed to form a batter 2. The batter 2 was treated in the same manner asthat employed in Embodiment 1 to form heated food bases. These foodbases were subjected to the same final baking process as that employedin Embodiment 1. The obtained products had no taste caused by an egg,but had crispness, lightness, taste which were not so different fromthose obtained in Embodiment 1.

Embodiment 3

Heating conditions:

1. The gap between the heating plates was equivalent to the thickness ofa heated food base (disc-shaped heated base).

In each case, the gap was 2.5 mm.

2. The heating temperature was 130° C., the temperature of the heatingplates was 160° C., and the heating time was 30 to 90 seconds.

Heating time: 60 seconds, 75 seconds, 90 seconds (120° C.); 60 seconds,75 seconds (140° C.); 45 seconds, 60 seconds (150° C.);

3. The features of heated food bases (disc-shaped bases) and thecontents of the remaining water (measured by a moisture meter producedby Ketto Co.,).

(1) First baking

    ______________________________________                                                      Feature of base                                                                         Water content                                         ______________________________________                                        (111) (130° C., 75 sec.)                                                               Yellow inclining                                                                          15.2%                                                             toward white, soft                                            (112) (130° C., 90 sec.)                                                               Yellowish white                                                                           14.8%                                             (121) (140° C., 60 sec.)                                                               Yellowish white                                                                           11.4%                                             (122) (140° C., 90 sec.)                                                               Yellowish white                                                                           9.8%                                              ______________________________________                                    

The heated food bases containing 12 to 15% of water were soft and, whenten sheets of such bases were packed in one bag and a load of 5 g/cm²was applied thereto, they were compressed but did not adhere to eachother, and were not broken by bending them at an angle of about 90°.

The heated food bases containing 9 to 12% of water were not compressedand adhered to each other by applying a load of 8 g/cm², and not brokenby bending at an angle of about 60°.

In each case, heated food bases with a lattice pattern having a heightof 1.5 mm and 10-mm squares were obtained. Although these heated foodbases can be eaten as they are because the starch of wheat flour isα-starch, if they are finally baked by further heating until the colorsthereof become light brown, bases for edible vessels having crispnessand a good taste can be obtained.

All the food bases (111), (112), (121) and (122) which were subjected tothe first baking were finally baked at 200° C. for 60 seconds. The finalproducts of the bases (111) and (112) were slightly brownish yellow andcontained 0.3 to 0.4% of water. The final products of the food bases(121) and (122) were brownish yellow and contained 0.3 to 0.2% of water.

Since any one of the above-described food bases is soft and no cracksare produced when it is bent at an angle of about 90°, for example, ifbags each containing ten sheets of the food bases are put in layers in acorrugated cardboard box and stored therein, they can be transferredwithout being compressed and adhered to each other.

The conditions of the second baking were the same as those used inEmbodiment 1, and the results of the final baking were the same as thoseobtained in Embodiment 1. Embodiment 4

A batter 2 was formed by well-agitating the ingredients shown in thetable in Embodiment 1, and then poured onto the under heating plate 10ashown in FIG. 1(a) which had a lattice pattern having 10-mm squares andthe surface of which was previously heated to about 160° to 180° C. Theupper heating plate 10b was pressed on the lower heating plate 10athrough the hinge 10c, and the batter 2 was baked by heating in such amanner that the temperature of the batter held between the two heatingplates 10a, 10b was kept at a temperature of about 130° to 150° C. for agiven time. The two heating plates 10a, 10b were then opened so that thebaked batter (disc shape) was separated therefrom to form a heated foodbase 11.

The conditions of pouring of the batter were as follows:

1. The amount of the batter poured at one time: about 25 to 30 g

2. The temperature of the upper and lower heating plates: 160° to 180°C.

3. The thickness of the batter poured was determined by the gap betweenthe two heating plates which was substantially equivalent to thethickness of the heated food base 11.

The conditions of heating were as follows:

1. The gap between the two heating plates was the thickness of theheated food base (disc-shaped base).

In each case, the gap was 2.5 mm.

2. The heating temperature was 140° C., the temperature of the heatingplates was 130° C. to 150° C., and the heating time was 40 to 90seconds.

    ______________________________________                                        Temperature    Time                                                           ______________________________________                                        140° C. 60 seconds, 75 seconds, 90 seconds                             150° C. 45 seconds, 60 seconds                                         ______________________________________                                    

3. The features of the heated food bases (disc shape) and the content ofremaining water (measured by a moisture meter produced by Ketto Co.,)after first baking.

(1) First baking

    ______________________________________                                        Heating conditions                                                                            Feature of base                                                                            Water content                                    ______________________________________                                        (111) 140° C., 90 sec.                                                                     Yellow       9.2%                                         (112) 140° C., 120 sec.                                                                    Yellow       8.8%                                         (121) 150° C., 90 sec.                                                                     Yellow       6.8%                                         (122) 150° C., 120 sec.                                                                    Light pink   4.6%                                         ______________________________________                                    

The heated bases containing 8 to 10% of water were slightly soft, andwhen ten sheets of the bases were packed in a bag and a load of 8 g/cm²was applied thereto, they were neither compressed nor adhered to eachother. The food bases were not broken by bending them at an angle ofabout 30°.

The heated bases containing 4 to 7% of water were hard, and when tensheets of the bases were packed in a bag and a load of 10 g/cm² wasapplied thereto, they were neither compressed nor adhered to each other.They could be bent at an angle of about 20°, but cracks were producedwhen they were further bent. If a plastic vessel was used fortransferring the bases, the bases would not be broken.

In each case, the heated food bases with a lattice pattern which wasformed in each surface and had a height of about 1.5 mm and 10-mmsquares were obtained. Although these heated food bases can be eaten asthey are, because the starch of wheat flour is α-starch, if the heatedfood bases finally baked by heating until the colors thereof becomelight brown, edible vessels with crispness and a good taste can beobtained.

When all the heated food bases (111), (112), (121), (122) were subjectedto second baking at 200° C. for 60 seconds, the final products of thefood bases (111), (112) were slightly yellowish brown and contained 0.1%or less of remaining water, and the final products of the food bases(121), (122) were brown and contained about 0.1% of remaining water. Inparticular, in the food bases having embossed lattice patterns, theupper surfaces of the lattice patterns were slightly scorched.

When the food bases were finally baked at 180° C. for 60 seconds, thefinal products were brownish yellow and contained substantially noremaining water.

In the heated food bases containing about 8 to 10% of remaining water,no cracks were produced therein when the bases were bent at an angle ofabout 30°. The heated food bases containing about 4 to 7% of remainingwater could be bent at an angle of about 10°. Therefore, when ten sheetsof each type of food base are put in each of the bags and, if required,the bags are stored in piles in a corrugated cardboard box, a corrugatedcardboard or a foamed plastic plate which serves as a cushioning mediumis interposed between respective bags put in layers so that the heatedfood bases can be transferred.

In Embodiment 4, the conditions of the second baking are the same thoseemployed in Embodiment 1, and the results obtained by the second bakingwere the same as those obtained in Embodiment 1.

As described above, in the present invention, when a batter 2 obtainedby kneading wheat flour, an oil or fat, sugar, an edible surfactant suchas an egg, and water is poured onto the heating plate 10a, spreadthereon, and heated, the batter 2 is heated at a relatively lowtemperature so that the starch contained in the batter 2 is changed toα-starch, the protein is coagulated by heat, and about 4 to 20% of waterremains. Therefore, even if a large amount of the water is added toflour as a main ingredient, since the baking is performed at a lowtemperature of about 110° to 160° C., all of many disadvantages ofconventional methods can be removed, for example, the energy requiredfor baking the batter can be reduced. In addition, when heated foodbases are delivered, since no cracks are produced in the heated foodbases even if they are bent at an angle of about 30°, the bases areneither deformed nor damaged in the course of transport. If the basesare slightly deformed, since the bases can be corrected during secondbaking (final baking), good edible vessels such as cones and tarts canbe obtained regardless of such deformation. Since an outlet for sellingice cream such as soft cream which uses edible vessels is provided onlywith an extremely simple toaster-like type of small final baking machineof about 200 to 300W and a cone forming machine, edible vessels can beformed for a short time, and only a small space is required forinstalling equipment, resulting in a great reduction in the cost ofequipment investment. Furthermore, usually-available electrical servicewill be adequate, and a pleasant smell is generated in sales outletsduring the baking of cones, thus attracting customers' interest. Sincethe operation of baking is simple and can be thus performed byinexperienced workers, such as part-time workers such as are often, ofnecessity, employed for selling ice cream at outlets, personnelmanagement can be simplified.

What is claimed is:
 1. A supply of intermediate products which can beindividually toasted to provide crisp edible vessels, comprising:aplurality of disk-like sheets of material partially baked from a battermixture of the following ingredients:

    ______________________________________                                        Ingredient          Parts by Weight                                           ______________________________________                                        wheat flour          80-120                                                   sugar               30-60                                                     oil or fat          10-30                                                     egg                 10-30                                                     glycerin mono-fatty acid ester                                                                    0.5-2                                                     powdered milk       3-5                                                       salt                0.5                                                       coloring and flavoring agents                                                                     small amount                                              water                 80-120,                                                 ______________________________________                                    

said sheets being at most slightly browned, having platen imprints onboth opposite faces thereof, and having a moisture content of more than7 percent to 20 percent by weight; said sheets being stacked a pluralityof sheets high, in a package containing at least ten such sheets.
 2. Thesupply of intermediate products of claim 1, wherein:said sheets are eachabout 2.5mm thick.
 3. The supply of intermediate products of claim 2,wherein:said sheets are waffle-patterned on one said face thereof.